Systems and methods for packaging solid pharmaceutical and/or nutraceutical products and automatically altering a random three dimensional arrangement of solid pharmaceutical and nutraceutical products into two dimensional arrangements or linear transmission channels

ABSTRACT

Systems and methods are provided for altering a random three-dimensional orientation of solid pharmaceutical or nutraceutical products into either a two-dimensional arrangement of solid products or for transferring the solid products directly into one or more linear transmission channels. At least one elongated straight edge member is periodically vertically displaced into the mass of solid products and the displacement of this straight edge structure alone or in combination with other rotating or displaceable structures facilitate reorientation of the solid products.

The present application is a continuation-in-part of my previously filed application, U.S. Ser. No. 11/467,127, filed on Aug. 24, 2006, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of automated solid pharmaceutical packaging systems. More specifically, the present invention is directed to automated systems and methods for automatically altering a random three dimensional arrangement of solid pharmaceutical and/or nutraceutical products into two dimensional arrangements or linear transmission systems.

2. Description of the Related Art

Currently, there are wide variety of known solid pharmaceutical product packaging systems and methods. These conventional packaging and dispensing systems and methods rely upon a variety of different techniques for selectively transmitting one or more solid pharmaceutical products into a package. For example, some of these known systems and methods utilize individual automated dispensing canisters provided in an array such that the array of canisters is arranged to selectively transmit a variety of different pharmaceutical products into a package via a common funnel. Typically, these known conventional systems rely upon a vertically stacked arrangement of the automated dispensing canisters so that a gravity feed path may be provided from the canisters to the common funnel.

Another, now known technique is disclosed in my prior United States and foreign patent applications which are directed to the automatic altering of two dimensional random arrangements of solid pharmaceutical and nutraceutical products into linear transmission channels for selective dispensing of the products and subsequent packaging. In this approach, the random two dimensional orientation of the solid pharmaceutical and nutraceutical products are altered so that they fill linear transmission channels that have selective escapements for the automatic individual dispensing of these products. This technique is used to fill solid pharmaceutical and nutraceutical packaging.

In the United States and throughout the world, as the aging population increases, there is a corresponding if not greater increase in the demand for patient medications. Yet another factor related to the increased demand for individualized solid pharmaceutical product packaging solutions is due to the fact that ever-increasing numbers of an aging population are relying upon greater numbers of medications which must be taken daily or in some cases several times in one day. Consequently, there is an ever increasing demand for pharmaceutical packaging products which are both extremely accurate and fast. Although the existing conventional systems quickly and accurately fill solid pharmaceutical product packages, there remains a need for improved throughput and greater efficiencies in the pharmaceutical packaging systems.

Accordingly, one object of the present invention is to provide systems and methods for automatically filling blister packages with solid pharmaceutical products both quickly and accurately. Another object of the present invention is to provide systems and methods for automatically altering a three-dimensional random arrangement of solid pharmaceutical or nutraceutical products into a two dimensional arrangement or directly into linear transmission channels. Another object and advantage of the present invention is to provide systems and methods which can provide greater throughput over existing conventional automated solid pharmaceutical packaging systems and methods. Other objects and advantages of the present invention will be apparent in light of the following summary and detailed description of the presently preferred embodiments.

SUMMARY OF THE INVENTION

As noted above, there are existing automated systems and methods for transferring a random two dimensional arrangement of solid pharmaceutical or nutraceutical products into linear transmission channels for subsequent packaging of these products. The known systems and methods rely upon an available two dimensional arrangement of solid pharmaceutical or nutraceutical products which could be processed by the system. In one approach, the system requires a two dimensional array of solid pharmaceutical or nutraceutical products secured between two planar structures defining a cavity therebetween. The requirement for having such a two dimensional arrangement of solid pharmaceutical and nutraceutical products has resulted in the study of efficient mechanisms for providing such a two dimensional arrangement and the inventors have discovered systems and methods for efficiently providing such an arrangement. Additionally, the inventors have discovered novel systems and methods for automatically altering a random three-dimensional arrangement of solid pharmaceutical products directly into linear transmission channels.

In accordance with a first preferred exemplary embodiment of the system, a random three-dimensional orientation of solid pharmaceutical or nutraceutical products is provided in a space having two planar structures defining a funnel preferably located at a central bottom portion of the three-dimensional space. The two planar structures are preferably angled toward one another to direct the solid pharmaceutical or nutraceutical products toward a linearly arranged opening in the bottom of the three-dimensional space.

In accordance with a first preferred exemplary embodiment, at least one vertically displaceable straight edge extends along one side of the linearly arranged opening in the bottom of the three-dimensional space. It is preferred that two displaceable straight edge members extending along each opposed side of the linearly arranged opening in the bottom of the three-dimensional space are provided. Air pistons, motors having cams for driving the displacement of the straight edge structures or solenoids are provided.

In a first preferred embodiment, if only a single straight edge member is provided, the straight edge member is periodically displaced upward into the three-dimensional cavity containing solid pharmaceutical or nutraceutical products and is thereafter dropped backdown to its original position. The periodic motion of the straight edge structure into the three-dimensional mass of solid pharmaceutical or nutraceutical products causes the products to exit the bottom of the space into a two dimensional space provided there below.

In an alternate embodiment, when first and second straight edge members are provided, each is vertically displaced upward into the mass of solid pharmaceutical or nutraceutical products. They may be displaced vertically into the mass in unison or preferably are alternately driven into the mass to provide a more efficient altering of the random three-dimensional arrangement into the two dimensional cavity provided below the three-dimensional cavity.

In yet another alternate preferred embodiment of the present invention, a single straight edge member is provided along a first side of the linearly arranged opening in the bottom of the three-dimensional space. An elongated roller is positioned along the opposite side of the linearly arranged opening in the bottom of the three-dimensional space. The single straight edge member is periodically displaced into the random three-dimensional arrangement of solid pharmaceutical or nutraceutical products. The roller member is driven either periodically or continuously to more efficiently alter the random three-dimensional orientation of solid pharmaceutical or nutraceutical products into the two dimensional space provided below the three-dimensional cavity. The roller member may be provided with one or more bumps along a surface thereof to further improve the efficiency of translating the three-dimensional arrangement of solid products into a two-dimensional arrangement. The bump or bumps may extend across an entire length of the roller. Alternately, a plurality of bumps may be provided across a surface of the roller.

In yet another alternate arrangement, the straight edge structure of the present invention is operated in conjunction with displaceable wedge-shaped members which may also be displaced into or toward the mass of three-dimensional mass of solid pharmaceutical or nutraceutical products. In such an arrangement, the displacement of the straight edge structure in conjunction with the motion of the wedge-shaped members into the three-dimensional mass can be used for the purpose of directly transferring solid pharmaceutical or nutraceutical products from a random three-dimensional orientation into linear transmission channels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a first exemplary embodiment of a preferred arrangement having first and second displaceable straight edge members;

FIG. 2 is a perspective view which illustrates the structure of the first exemplary embodiment;

FIG. 3 illustrates the two displaceable straight edge structures of the first exemplary embodiment;

FIG. 4 is a side view which illustrates the overall arrangement of the first preferred exemplary embodiment;

FIG. 5 illustrates details of a second exemplary embodiment of the present invention utilizing a displaceable straight edge structure and roller member;

FIG. 6 is a perspective view which illustrates the roller and straight edge structure of the second embodiment; and

FIG. 7 is a side view which illustrates the overall structure of the second exemplary embodiment.

DETAILED DESCRIPTION OF THE PRESENT PREFERRED EMBODIMENTS

FIG. 1 illustrates a first preferred exemplary embodiment of the system shown generally at 10 wherein a random three-dimensional orientation of solid pharmaceutical or nutraceutical products are automatically transferred into a two-dimensional space. In accordance with the preferred exemplary embodiment, a three-dimensional cavity 12 is filled with a random orientation of solid pharmaceutical or nutraceutical products. Mechanical baffles 14, 16, 18 are provided to diminish the amount of weight and downward force applied to the orientation mechanisms. The mechanical baffles structures 14, 16, 18 simply prevent the overall mass contained within the three-dimensional cavity 12 from jamming the mechanical movement.

Two planar structures 21, 22 define a funnel that is preferably located at a central bottom portion of the three-dimensional cavity 12. The two planar structures 21, 22 are preferably angled toward one another to direct the solid pharmaceutical or nutraceutical products toward a linearly arranged opening in the bottom of the three-dimensional space 12.

In accordance with a first preferred exemplary embodiment, at least one vertically displaceable straight edge 23 extends along one side of the linearly arranged opening in the bottom of the three-dimensional space 12. It is preferred that two displaceable straight edge members, elements 23, 24, extend along each opposed side of the linearly arranged opening in the bottom of the three-dimensional space. Air pistons, motors having cams for driving the displacement of the straight edge structures or solenoids are provided for the purpose of upwardly driving at least one or possibly two straight edge members 23, 24 from a position where an uppermost edge of the straight edge 23, 24 is at a lowermost portion of the funnel defined by planar members 21, 22 to location such that the uppermost straight edge is displaced into the mass of solid pharmaceutical or nutraceutical products.

In a first preferred embodiment, if only a single straight edge member 23 is provided, the straight edge member is periodically displaced upward into the three-dimensional cavity containing solid pharmaceutical or nutraceutical products and is thereafter moved back down to its original position. The periodic motion of the straight edge structure into the three-dimensional mass of solid pharmaceutical or nutraceutical products causes the products to exit the bottom of the space into a two dimensional space provided there below thereby achieving a two-dimensional orientation for the products.

In an alternate embodiment, when first and second straight edge members 23, 24 are provided, each is periodically vertically displaced upward into the mass of solid pharmaceutical or nutraceutical products. As noted, air pistons, motors having cams for driving the displacement of the straight edge structures or solenoids are provided for this purpose. The first and second straight edge members 23, 24 may be displaced vertically into the mass in unison or preferably are alternately driven into the mass to provide a more efficient altering of the random three-dimensional arrangement into the two dimensional cavity provided below the three-dimensional cavity.

FIG. 2 is a cut away illustration which shows the cavity having baffles 14, 16, 18 and one of the planar structures 22 defining the funnel portion at the bottom of the three-dimensional cavity. Straight edge members 23, 24 extend across the base of the cavity adjacent to planar structures 22, 23, only one of which is shown. Sidewalls 26, 28, provide support for baffles, 14, 16, 18 and also define side boundaries of the three-dimensional cavity. The sidewalls 26, 28 preferably include slots within which the straight edge members 23, 24 are displaced as noted above.

FIG. 3 illustrates portions of the overall structure such as the straight edge members 23, 24, and sidewalls 26, 28 having slots formed therein which allow vertical displacement of the straight edge members 23, 24, as described above.

FIG. 4 illustrates another alternate preferred exemplary embodiment of the present invention wherein a single straight edge member 23 is provided along a first side of the linearly arranged opening in the bottom of the three-dimensional space 12. An elongated roller 30 is positioned along the opposite side of the linearly arranged opening in the bottom of the three-dimensional space 12. All of the remaining structures described with regard to the first embodiment are the same and have been numbered accordingly.

The single straight edge member 23 is periodically vertically displaced into the random three-dimensional arrangement of solid pharmaceutical or nutraceutical products. The roller member 30 is also rotatably driven either periodically or continuously to more efficiently alter the random three-dimensional orientation of solid pharmaceutical or nutraceutical products into the two dimensional space provided below the three-dimensional cavity 12.

The roller member 30 may be provided with one or more bumps along a surface thereof to further improve the efficiency of translating the three-dimensional arrangement of solid products into a two-dimensional arrangement. The bump or bumps may extend across an entire length of the roller. Alternately, a plurality of bumps may be provided across a surface of the roller. These bumps have not been shown for the sake of convenience but should provide a minor extension above the surface of the roller 30 to thereby provide an alternate structure which randomly engages the solid pharmaceuticals or nutraceuticals contained within the cavity 12 during rotation of the roller 30.

FIG. 5 illustrates portions of the structure described with reference to the second embodiment described in FIG. 4. As shown in FIG. 5, sidewalls 26, 28 are each provided with a single slot that enables the straight edge member 23 to be displaced vertically into the three-dimensional cavity located above. The roller 30 which extends along the entire opening at the bottom of the cavity 12 is also very clearly shown in this illustration. FIG. 5 also illustrates a motor 32 for rotatably driving the roller 30 and/or vertically displacing the straight edge member 23.

In each of the embodiments described above, the vertical displacement of one or more straight edge members 23, 24 or the vertical displacement of a straight edge member operating in conjunction with a roller located at the bottom of a final in a three-dimensional cavity acts to facilitate the transfer of solid pharmaceutical and nutraceutical products from the three-dimensional space wherein their is a random three-dimensional array of the solid products into a cavity defined by to planar members which provides a two-dimensional array or orientation of the solid pharmaceutical or nutraceutical products.

FIG. 6 illustrates the detailed operation and preferred arrangement of the embodiments wherein a single vertically displaceable straight edge 23 is provided and which operates in conjunction with the roller 30 in order to alter the orientation of solid pharmaceutical or nutraceutical products contained within the three-dimensional cavity located between planar structures 21, 22. The single straight edge member 23 is periodically displaced into the random three-dimensional arrangement of solid pharmaceutical or nutraceutical products. The roller member 30 is driven either periodically or continuously to more efficiently alter the random three-dimensional orientation of solid pharmaceutical or nutraceutical products into the two dimensional space provided below the three-dimensional cavity. The roller member 30 may be provided with one or more bumps along a surface thereof to further improve the efficiency of translating the three-dimensional arrangement of solid products into a two-dimensional arrangement. The bump or bumps may extend across an entire length of the roller 30. Alternately, a plurality of bumps may be provided across a surface of the roller 30.

FIG. 7 illustrates yet another alternate preferred exemplary embodiment, wherein the one or more vertically displaceable straight edge structures of the present invention operate in conjunction with preferably a plurality of vertically displaceable wedge-shaped members which are also preferably moved upward and into or toward the mass of three-dimensional mass of solid pharmaceutical or nutraceutical products. In accordance with this alternate preferred exemplary embodiment, the upward displacement of the straight edge structure 23 is accompanied by upward vertical motion of at least some of the wedge-shaped members shown in the illustration into the three-dimensional mass of solid pharmaceutical and nutraceutical products.

In accordance with the preferred exemplary embodiment of FIG. 7, the vertically displaceable straight edge 23 is mechanically secured to a plurality of vertically displaceable wedge shaped members 52, 54, 56. In this preferred exemplary embodiment, the vertically displaceable wedge-shaped members 52, 54, 56 are secured directly to the vertically displaceable straight edge 23. This is preferred in order to limit the amount of driving mechanisms required for displacing straight edge and the wedge-shaped members. However, those skilled in the art will appreciate that independent vertical drive mechanisms may be provided for the vertically displaceable wedge-shaped members 52, 54, 56.

Static wedge-shaped members 53, 57, 59 are provided between the vertically displaceable wedge-shaped members 52, 54, 56. The interaction of the wedge-shaped members is similar to that described in my earlier application Ser. No. 11/467,127 filed on Aug. 24, 2006 wherein a two-dimensional orientation of solid pharmaceutical or nutraceutical products is altered into one-dimensional arrangement in linear transmission channels. Consistent with the earlier application, linear transmission channels 61, 62, 63, 64 are provided beneath the space between the displaceable and static wedge-shaped members. The operation and motion of the wedge-shaped members in conjunction with the straight edge provides a direct translation of the orientation from the random orientation of the solid pharmaceutical products in the three-dimensional space directly into the linear transmission channels 61, 62, 63 and 64 provided in the space between the displaceable and static wedge-shaped members. This preferred exemplary embodiment may be used for the purpose of directly transferring solid pharmaceutical or nutraceutical products from a random three-dimensional orientation into linear transmission channels.

Those skilled in the art will appreciate that an additional vertically displaceable straight edge structure may be provided which operates in conjunction with the straight edge structure illustrated in FIG. 7 having the vertically displaceable wedge-shaped members secured thereto. In an alternate arrangement, some of the vertically displaceable wedge-shaped members may be secured to each of the to vertically displaceable straight edge structures. In yet another alternate arrangement, a roller may be used in conjunction with a vertically displaceable straight edge having wedge-shaped structure secured thereto. It should be recognized that the linear opening in the bottom portion of the housing is typically longer than at least three times the longest dimensions of the solid products contained within the housing.

The inventors have discovered that the embodiments of the present invention which employ the use of at least one vertically displaceable straight edge alone and/or operating in conjunction with a second vertically displaceable straight edge are preferred for altering the random three-dimensional orientation of solid pharmaceutical and nutraceutical products having cylindrical symmetry such as capsules or almost cylindrical symmetry such as caplets and/or tablets. For solid pharmaceutical products and/or nutraceuticals having a disk shape, where a diameter of the medication is larger than its thickness, it is preferable to incorporate the roller structure. The inventors have discovered that this general relationship provides the greatest deficiency.

Those skilled in the art will appreciate that various alterations or combinations of the structures described with regard to the preferred exemplary embodiments may be provided without departing from the spirit and scope of the invention defined by the appended claims. 

1. A system for altering a random three-dimensional arrangement of solid products comprising: a housing having a linear opening in a bottom portion thereof and a plurality of solid products located within the housing in a random three-dimensional orientation, the linear opening being more than three times longer than a greatest dimension of the solid products contained within the housing; a first vertically displaceable straight edge located immediately adjacent the linear opening in the bottom portion of the housing and extending substantially an entire length of the linear opening in the bottom portion; a drive mechanism for periodically vertically displacing the straight edge into the random three-dimensional orientation of solid products.
 2. The system for altering a random three-dimensional arrangement of solid products of claim 1, further comprising a second vertically displaceable straight edge located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and extending substantially an entire length of the linear opening in the bottom portion.
 3. The system for altering a random three-dimensional arrangement of solid products of claim 1, further comprising an elongated roller located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and extending substantially an entire length of the linear opening in the bottom portion.
 4. The system for altering a random three-dimensional arrangement of solid products of claim 1, further comprising at least one vertically displaceable wedge shaped member located immediately adjacent the first vertically displaceable straight edge.
 5. The system for altering a random three-dimensional arrangement of solid products of claim 4, wherein the at least one vertically displaceable wedge shaped member is secured to the first vertically displaceable straight edge.
 6. The system for altering a random three-dimensional arrangement of solid products of claim 4, further comprising a second vertically displaceable straight edge located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and extending substantially an entire length of the linear opening in the bottom portion.
 7. The system for altering a random three-dimensional arrangement of solid products of claim 4, further comprising an elongated roller located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and extending substantially an entire length of the linear opening in the bottom portion.
 8. The system for altering a random three-dimensional arrangement of solid products of claim 1, further comprising a cavity located beneath the linear opening, the cavity having shortest dimension only slightly larger than a shortest dimension of the solid products and the remaining dimensions being substantially greater so that the cavity is capable of receiving a two-dimensional random orientation of the solid products.
 9. A method for altering a random three-dimensional arrangement of solid products comprising: providing a plurality of solid products in a housing having a linear opening in a bottom portion thereof the solid products located within the housing in a random three-dimensional orientation, the linear opening being more than three times longer than a greatest dimension of the solid products contained within the housing; vertically displacing a straight edge member into the random three-dimensional arrangement of solid products, wherein the straight edge is located immediately adjacent the linear opening in the bottom portion of the housing and extending substantially an entire length of the linear opening in the bottom portion; and periodically vertically displacing the straight edge into the random three-dimensional orientation of solid products to thereby facilitate transfer of the solid products from the random three-dimensional orientation into a space below the linear opening.
 10. The method for altering a random three-dimensional arrangement of solid products of claim 9, further comprising vertically displacing a second straight edge into the solid products, wherein the second straight edge is located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and extending substantially an entire length of the linear opening in the bottom portion.
 11. The method for altering a random three-dimensional arrangement of solid products of claim 9, further comprising rotating an elongated roller located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and which extends substantially along an entire length of the linear opening in the bottom portion, the rotation of the elongated roller being performed to thereby facilitate transfer of the solid products from the random three-dimensional orientation into a space below the linear opening.
 12. The method for altering a random three-dimensional arrangement of solid products of claim 9, further comprising vertically displacing at least one wedge shaped member toward the solid products, wherein the wedge shaped member is located immediately adjacent the first vertically displaceable straight edge.
 13. The method for altering a random three-dimensional arrangement of solid products of claim 12, wherein the at least one vertically displaceable wedge shaped member is secured to the first vertically displaceable straight edge.
 14. The method for altering a random three-dimensional arrangement of solid products of claim 12, further comprising vertically displacing a second straight edge that is located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and which extends substantially an entire length of the linear opening in the bottom portion.
 15. The method for altering a random three-dimensional arrangement of solid products of claim 12, further comprising rotating an elongated roller located immediately adjacent the linear opening in the bottom portion of the housing at a side opposite the first vertically displaceable straight edge and which extends substantially an entire length of the linear opening in the bottom portion.
 16. The method for altering a random three-dimensional arrangement of solid products of claim 1, further comprising transferring the solid products into a cavity located beneath the linear opening, the cavity having shortest dimension only slightly larger than a shortest dimension of the solid products and the remaining dimensions being substantially greater so that the cavity is capable of receiving a two-dimensional random orientation of the solid products. 